Aeroseal Duct Sealing: How It Works and Is It Worth It?

What Is Aeroseal?

Aeroseal is a patented duct sealing technology developed at Lawrence Berkeley National Laboratory and commercialized for residential use. Unlike traditional duct sealing methods that require access to every joint and connection, Aeroseal works from the inside of your ductwork—sealing leaks you can't see and often can't reach.

It's one of the most significant advancements in residential HVAC efficiency in the past two decades, and it's particularly valuable for homes in Atlantic Canada where heating costs are a major household expense.

How the Aeroseal Process Works

Step 1: Diagnostic Testing

Before any sealing begins, we perform a duct leakage test to measure exactly how much air your system is losing. This gives us a precise baseline and helps determine whether Aeroseal is the right solution for your home.

Step 2: Preparation

All supply registers and return grilles are temporarily blocked. The HVAC system is sealed off from the ductwork to protect the equipment.

Step 3: Sealant Application

A non-toxic, water-based sealant is atomized into a fine mist and injected into the pressurized duct system. As the pressurized air escapes through leaks, the sealant particles accumulate at the leak points, gradually building up until the leak is sealed.

Think of it like this: imagine blowing air through a straw with a tiny hole. If you introduce fine particles into the airstream, they'll naturally collect at the hole. Aeroseal works on the same principle, just at a larger scale.

Step 4: Verification

Throughout the process, computer software monitors the sealing in real time, showing exactly how much leakage is being eliminated. After completion, a final diagnostic test measures the improvement. Most homes see 80% to 95% reduction in duct leakage.

Is Aeroseal Worth the Investment?

This is the question everyone asks, and the honest answer is: it depends on your situation. Here's who benefits most:

Ideal Candidates

• Homes with rooms that are hard to heat or cool: If certain rooms are always too hot or too cold despite adjusting registers, duct leaks are likely the cause
• Older homes with original ductwork: Ducts installed decades ago often have significant leakage at joints that have loosened over time
• High energy bills: If your heating costs seem disproportionate to your home's size, duct leakage may be wasting a substantial portion of your energy
• Homes with ducts in unconditioned spaces: Ducts running through attics, crawlspaces, or unheated basements lose the most energy when they leak
• Excessive dust: Leaky return ducts pull in unfiltered air from crawlspaces and wall cavities, bringing dust and contaminants into your living spaces

When Aeroseal May Not Be Necessary

• Newer homes (built after 2010) with properly installed ductwork that passes a blower door test
• Homes where ductwork is entirely within conditioned spaces and leakage is minimal
• Ductwork that is severely damaged or collapsed—in these cases, replacement may be more appropriate

Cost and Return on Investment

Aeroseal typically costs between $799 and $1,500 for a standard residential system, depending on the size and complexity of your ductwork. While this is a meaningful investment, the returns can be substantial:

• Energy savings: Homeowners typically see 15% to 30% reduction in heating and cooling costs
• Comfort: Even temperature distribution throughout the home, eliminating hot and cold spots
• Air quality: Sealed ducts prevent unfiltered air, insulation particles, and contaminants from being drawn into your system
• Equipment longevity: Your HVAC system doesn't have to work as hard to compensate for lost air

For many Nova Scotia homeowners, the energy savings alone pay for the Aeroseal treatment within two to four heating seasons.

Aeroseal vs. Traditional Duct Sealing

Traditional duct sealing involves a technician manually applying mastic or metal tape to visible joints and connections. While effective for accessible ductwork, it can't address leaks in hidden locations—behind walls, in tight crawlspaces, or at joints deep within the system.

Aeroseal reaches every leak in the system, regardless of accessibility. The computerized monitoring also provides precise before-and-after measurements, giving you documented proof of improvement.

The Aeroseal Warranty

Aeroseal sealant is rated to last the lifetime of the ductwork—typically 25 years or more. The product has undergone independent testing and meets UL safety standards. The sealant is non-toxic, water-based, and contains no volatile organic compounds.

Interested in seeing if Aeroseal is right for your home? Request a free duct leakage assessment or call (902) 555-0123. We'll give you an honest evaluation of your system's condition and whether Aeroseal would provide meaningful benefit.